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CREATING NEW DIMENSIONSin SUSTAINABLE BUILDING TECHNOLOGY
FIRE RATED INSULATED WEATHERTIGHT GREEN IWALLS CEILINGS ROOFS ICOMMERCIAL INDUSTRIAL ARCHITECTURAL RESIDENTIALFEATURES UTILISATION APPLICATION
0800 430 430Email [email protected] www.bondor.co.nz
StructuralInsulated
PanelGuide
2011
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Bondor New Zealand Ltd is a nationally established manufacturer of structural insulated panels,
fire rated insulation materials and expanded polystyrene (EPS) construction products. With over
40 years of trading experience in manufacturing and construction we are recognised as the
market leader in our industry we take pride that our name is associated with integrity and
professionalism.
With manufacturing sites in Auckland and Christchurch and branches in Dunedin and the Bay of Plenty, we provide an integrated
approach to the construction and supply of our products. Our construction teams travel throughout New Zealand, providing
professional and reliable advice to all our clients; and we like to do things to specification, on time and in full. Our services include:
Bondor New Zealand also offers and supplies a warranted installationservice as well as a complete range of flashings, aluminium extrusions,insulated doors and construction components.
INTRODUCTION TO BONDOR NEW ZEALAND
Services
National coverage for installationOur professional construction teams areconstantly travelling throughout New Zealand
for our clients. We have panel manufacturingplants in Auckland and Christchurch and
regional offices in Mt Mauganui and Dunedin
ensuring our staff and products are alwaysreadily available.
The flexibility to engage in buildingworks from design assistance andbuild through to a subcontractcapacityTo ensure our customers get the most
benefits from the construction spectrum,
we are comfortable in assisting with a fulldesign and build service though to being
engaged in a sub-contract capacity.No job is too big or too small.
Experienced, professional,construction staffFrom estimating through to practicalcompletion we have a commitment to
doing it once, doing it right, to specification,
on time, and in full.
Competitive supply ratesWe can provide fixed prices and short
lead times. We also offer the full range ofcomponents for constructing insulated panel
buildings.
Warranty and certificationBecause weve been around for four
decades, we stand by our workmanship,products and brands.
Technical information and CAD detailsAre all available online at www.bondor.co.nz
or call us for a hard copy. Insurance and firerating requirements for insulated panel can
be confusing contact one of our technical or
sales staff for some balanced advice.
XFLAMTo consolidate our position as a market
innovator, we have adopted XFLAM as one
of our leading brands. XFLAM is a globally
developed fire rated insulating material
that delivers exceptional solutions for the
construction of temperature controlled and
energy efficient buildings.
At Bondor New Zealand, we are committedto a healthy environment; our products aretruly green and sustainable, both in form andfunctionality. We strive to ensure that thesustainability features of our products are thebest for people, profits and the planet.
Uses
Bondor NZ structural insulated panelshave been produced in New Zealand
for more than 40 years during which
time have been used in the following
applications:
Controlled atmosphere storage, freezers,chillers, roofing, architectural cladding, highrise apartments, facades, distribution centres,gymnasiums, portable buildings, interior fitouts, partitions, commercial kitchens, producestorage, wineries, temperature controlledenvironments, laboratories, blast freezers,supermarkets, food processing facilities, dairyfactories, rearing sheds, cow sheds, residentialroofing, pharmaceutical manufacture, piggeries,
fish processing, canopies, bakeries, archives,swimming pools, stadium roofs, incubationfacilities, poultry sheds, kennels, housing,warehouses with offices.
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Passive temperaturecontrol
Fully encapsulated pre-finishedpanels containing Bondor New
Zealands range of insulating
core materials provide a
guaranteed and continuous
insulation rating, suitable for
all ambient and refrigerated
applications. When used as a
roofing product radiant heat
transfer and condensation build
up is eliminated.
Flexible designBondor New Zealands insulated
panel can clad vertically or
horizontally. There are three
different profile finishes andtwo roof profiles that can be
combined with a wide choice of
colours, including metallics, and
specialist paint finishes suitable
for both interior and exterior
applications.
Cost effectivespanning capabilitiesInsulated panels provide
excellent spanning capabilities
and are self supporting to long
lengths. Suitable for both load
bearing and non-load bearing
applications the structural detail
and framing requirements areminimal when compared to other
roof and cladding products.
Seismic PerformanceThe lightweight modular nature
of Bondor Panel, particularly
with and EPS or XFLAM core,
produces minimal lateral loading
during an earthquake. This force
is comfortably accommodated by
the high bracing capacity of the
panel and the high strength of
the steel facings and associated
fixings. The steel skin also
provides significant protection
from falling objects. Thestructural couplings and fixings
are accessible for post event
damage inspection and repair.
Fire ratedChoose from the range of
Bondor New Zealands panelcores to meet the requirements
of global insurers and the
standards required in the New
Zealand and Australian Building
codes. The ranges of cores have
been comprehensively tested.
Bondor New Zealands Mineral
Wool and XFlam panels meet
the requirements of the NZBC
for a 30 or 60 minute fire rating
(FRR) as well as FM Global 4880
Class 1.
Fast build timesThe modular nature of insulated
panel can significantly reducebuild times. The Slip Joint panels
arrive on-site pre-finished and
are installed efficiently using
single fix construction techniques.
There are no curing times and
no multi-product combinations
to cause delays.
Made in New ZealandBondor panel is made in state-
of-the-art manufacturing plants
in Auckland and Christchurch.
All panels are manufactured to
the required length ensuring
continuous watertight panels and
no waste.
Production flexibility, the fast turn
around of orders, and short runs
are a feature of Bondor New
Zealands manufacturing
capabilities. Bondor New
Zealands unique position of
having operations in both
islands minimises transport, thus
reducing one of the contributors
to global warming.
Advanced insulationratings
Bondor New Zealands panelthicknesses provide a simple
solution to achieving a full
spectrum of insulation ratings
greater than the requirements
of the Building Code. Through
improving the insulation values,
the amount of fuel or energy
required to heat or cool a
building is reduced, benefiting
the environment and providing
savings to the building user.
Energy efficientGreen buildingsThe efficient control of energy
within the finished building andthe short build times offset the
minimal environmental impact
of the panels manufacture and
installation. Ongoing energy
savings are made through
outstanding climate control,
provided by the panels
continuous insulation properties,
reducing heating, refrigeration
and air conditioning costs. All
Bondor New Zealand insulation
cores can be recycled or
remanufactured at the end of
their useful life.
Low maintenanceand hygienicThe steel profiles and paint
finishes provide an easily cleaned,
hygienic, low maintenance
sterile surface approved for food
processing, food preparation and
cool storage facilities.
F
A
D
C
B
E
D
C
E
B
F
F
A Prefinished steel skin
Insulating core
Female slip joint
Male slip joint
Easy & effective slip joint installation
Rigid weathertight connection provides
continuous insulation and resistance to
fire deformation
Slip Joint technologyEvery panel incorporates Bondor New Zealands Slip Joint technology.
This uniquely designed system incorporates a male and female joint
on each steel face that provides a rigid and sealed connection between
adjacent pawhe tightness and quality of the joint resists deformity in fire
situations, provides a weathertight seal and enables effective and easy
installation.
THE ADVANTAGES OF BONDOR NEW ZEALANDSSTRUCTURAL INSULATED PANEL
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WALLS, CLADDINGS AND FACADESWall panels can be installed horizontally or vertically. Finished panels can be any combination of wall profile.
PANEL PROFILES
FLAT
SHADOWLINE
EPS, MINERAL WOOL or XFLAM CORE
50-300mm
EFFECTIVE WIDTH 1200mm
RIBBED
Micro Ribbed
EPS, MINERAL WOOL or XFLAM CORE
50-300mm
EFFECTIVE WIDTH 1200mm
EPS, MINERAL WOOL or XFLAM CORE
50-300mm
EFFECTIVE WIDTH 1200mm
THE RANGEBondor New Zealands range of structural insulated panel technologies providesystems that enable the fast and cost effective construction of energy efficient, controlled environment,and fire rated buildings.
SATINLINE Microcorrugate
EPS, MINERAL WOOL or XFLAM CORE
-
EFFECTIVE WIDTH 1200mm
Satinline XFLAM Panel installed horizontally Flat EPS Panel installed vertically Titania
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EPS, MINERAL WOOL or XFLAM CORE
50-250mm
250mm
32mm
EFFECTIVE WIDTH 1000mm
50-250mm
250mm
33mm
EFFECTIVE WIDTH 1000mm
1018mm
EPS
METRIC 5-Rib
Bondor NZs prefinished metric roofing panels are a fully insulatedthrough fixed roof and ceiling system that is extremely fast toinstall requiring only one trade.The external continuous uniform end lap combined with an internalslip joint detail and insulated core provides an instant weather tightand thermally efficient roof with a prefinished ceiling.Metric roofing panels offer many advantages over traditional builtup systems including reduced installation costs, improved levels ofair tightness and no risk of condensation or cold bridging.
With better spanning capabilities and fewer purlins than traditionallong run roofing, the installation time is reduced and therequirement to install underlays, foils, building papers, mesh andblankets is eliminated.Savings of up to 25% can be made on both material and labour incomparison to conventional roofing systems.Ideal for where exposed rafters and purlins are detailed and forresidential applications a thickness between 150mm and 200mm isrecommended.
North Island Profile
South Island Profile
Metric XFLAM Metallic Silver Metric EPS Titania
ROOFING AND CANOPIES
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XFLAMXFLAM is a breakthrough product in the field of fire-resistant panel.It is a syntactic foam with
enhanced fire resistance, excellent mechanical properties, superior insulation values, low toxicity
and is completely recyclable. XFLAM combines the best attributes of Polyfoam EPS and phenolics
with new attributes of its own.
Developed initially as a high performance core for panel systems, XFLAM also has applications
in many other areas. XFLAM provides the following benefits:
XTRA Fire Resistance and Fire RatingsXFLAM consists of EPS pre-expanded beads with a hybrid phenolicresin, a catalyst, lightweight additives and carbon. The resin has highadhesive bond energy. It is hard to break down under fire energy andeliminates the exposure of the EPS bead to the flame source. At 1200Cthe phenolic honeycomb matrix remains intact and the fire behaviour islimited to surface charring which significantly delays the fire spread andprotects the core.
In comparison to other RCPs (rigid cellular plastics) such as PIR(polyisocyanurate and PUR (polyurethane) XFLAM provides superiorfire resistance. It achieves its FM Approval with simple and costeffective construction details and is the only RCP that achieves aGroup 1 BCA classification.
XFLAM meets global insurance
requirements: Factory Mutual Global. FM Wall - Ceiling Construction. Reference 3035839 Bondor New Zealand Ltd,
3025087 and 3029819 Austral Comnia Holdings PTY Ltd. Meets all the requirements of FM Approvals Standard 4880
for Metal-faced Building Insulations. Class 1 Fire Rated to max 9.1m High. Test Standard UBC 26.3.
XFLAM meets the NZ and Australianbuilding codes for fire resistance:
AS1530.4 Fire Resistant Test: 50mm panel - /120/15
INTEGRITY RATING 120mins INSULATION RATING 15mins 100mm panel - /120/30
INTEGRITY RATING 120mins INSULATION RATING 30mins
250mm panel - /120/115INTEGRITY RATING 120mins INSULATION RATING 115mins
ISO9705 Corner Room Test achievedGroup 1 BCA Classification.
Passes theFlame Barrier requirements for foamed plastics under theAcceptable Solution C/AS1 part 6 of the NZBC.
Specifiers and building owners can be confident when they use XFLAMthey are fulfilling the requirement of the New Zealand and AustralianBuilding Codes, Territorial Authorities and the insurance industry.
TM
Fire Rated & Architectural Panel Systems
PANEL CORES XFLAM
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XTRA Thermal PerformanceAs an insulating material XFLAM achieves a higher insulation ratingthan EPS or mineral wool.
Very low water transmission rates ensure XFLAM can be used in anyapplication previously regarded as the preserve of EPS, PUR, and PIRpanel.
Greater insulation value reduces the energy costs for maintainingcomfortable and efficient environments in the building.
XTRA StrongAs a construction product XFLAM has superior mechanical propertiesto EPS, PIR, PUR and mineral wool. It can span up to 30% further thanPIR and PUR reducing the cost of supporting structures and freeing up
internal spaces.
XFLAM provides extra strength and rigidity that enables long spanssuitable for use in the walls, ceilings, roofs and facades of all buildings.
XFLAM can be used as structural unit in commercial and residentialconstruction.
XFLAM is suitable for use as trafficable ceiling.
Structural costs can be significantly reduced through using XFLAM panel,in comparison to other building materials and insulated panels.
XFLAM does not require extra structural components to achieve its fireratings.
XTRA SustainableNo blowing agents are used in the manufacture of XFLAM.
XFLAM waste can be returned to the manufacturing process, andbecause its made locally, the carbon footprint of transportis minimal.
Its advanced insulation ratings ensure that energy consumption isreduced preserving the natural resources of the planet.
Sustainable construction is a critical factor in the consideration ofbuilding materials. XFLAM insulated panel ticks all the boxes and more.
XTRA SafeXFLAM is compliant with both aircraft and underground rail fireresponse requirements.
In a fire situation combustion is restricted to small clean burning cellswith very little smoke production and negligible toxic species.
Construction teams can easily work with XFLAM - protective work wear isnot required.
XTRA StableExtruded rigid cellular plastics such as PIR and PUR commonly sufferfrom out gassing, a post-production phenomenon that results insignificant loss of thermal insulation over time and deformation of thepanel and the likely release of toxic compounds into the environment.
XFLAM like EPS, provides astable and guaranteed thermal rating and is harmless and inert at thetime of its manufacture into panel.
XTRA ValueDollar for dollar, XFLAM achieves better thermal resistance (R-value)than PIR and PUR systems.Savings of up to 30% can be made when calculating the costs of
the panel system and the appropriate structural supporting elementstogether.
When considering the total construction cost of building, XFLAM offerssignificant cost savings in the reduction of structural elements whileoffering superior insulation values in comparison to other RCPs.
PANEL CORES XFLAM
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Mineral wool is manufacturedfrom molten rock, glass or slagthat is spun into wool-like fibreand bound with resin. Thefibres are compressed whichtrap air creating insulation andsound control attributes.
Classified as non-combustible,mineral wool does not conductheat and can withstand
temperatures above 1000C.
Where noise control isimportant mineral woolprovides significantacoustic ratings.
The inorganic nature andbonded structure of mineralwool makes it vermin andinsect proof.
Recommended for completebuildings, constructing fire cells,partition walls, and isolatingplant rooms wherethe ambient temperature isabove 5C.
Suitable also for cool storesand freezers with correctinstallation, and vapourbarrier installed.
At the end of its usefullife, mineral wool can bereprocessed or returned tothe earth without furthercontainment.
PANEL CORES EPS: MINERAL WOOL
MINERAL WOOL
Polyfoam EPS is the industryproven core used in insulatedpanel construction for morethan 40 years including theoriginal Rudnev panel. It isideally suited in temperaturecontrol applications and hasan impressive strength toweight ratio.
Polyfoam EPS is the costeffective solution to risingbuilding costs and itsexceptional lightweight
properties provide furthersavings in the costs forfoundations, framingand installation.
EPS has a significantsustainable advantage in that itis completely recyclable.
Bondor New ZealandsPolyfoam EPS panel meets theNZBC acceptable solutionC/AS1 for foamed plastics, andwhen detailed to Bondor NewZealands tested specificationachieves a fire resistance240/240/- rating for non-load
bearing walls.
The raw material used containsa fire retardant that is self-extinguishing. Burning it onlyresults in water vapour, carbondioxide and trace levels of ashsimilar to paper, and is lessharmful than burning timber.
In normal conditions energysaved in the first six monthsof a building constructed fromPolyfoam EPS panel is morethan the total energy used tomanufacture Polyfoam EPS
and convert it to an insulatingmaterial.
Polyfoam EPS has a lowcarbon footprint. It is a by-product obtained during therefining process of crude oil.The main component used inits manufacture as an insulatingmaterial is steam with anywaste water being recycledback through the steamingprocess.
Suitable for extremeenvironments.
POLYFOAM EXPANDED POLYSTYRENE (EPS)
Insulated Panel
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CORE COMPARISONS
TABLE 1
FIREPERFORMANCE
XFLAM MINERAL WOOL EPS (Polyfoam)
Insurer Approved YesFM 4880 Class 1
YesFM 4880 Class 1
YesCan depend on risk assessment
Fire rating of elementsAS 1530.4BS 476 pt22-24LPS 1208 and equivalents
- / 120 / 1550mm panel- / 120 / 30
100mm panel- / 120 / 115
250mm panel
- / 60 / 60100mm panel- / 120 / 90
150mm panel- / 240 /240
200mm panel
- / 240 / 0100mm panel
Flame barrierNZBC C/AS1 part 6
Yes Not required.Not a foamed plastic
Yes
ISO 9705
BCA Classification
Group 1 Group 1
Non-Combustible
Group 1* & 2
SMOGRASMOkeGrowthRAte
2.2 NA 3.8
Toxicity Very LowCO, CO2
Non Flammable LowCO, CO2, C
* Specific construction system required.
TABLE 2
ENGINEERINGDETAILS(Core materialonly unlessotherwise stated)
XFLAM MINERAL WOOL EPS (Polyfoam)
Density 32 kg/m3 100 kg/m3 16 kg/m3
Water absorptionASTM C272
Very Low NA Very Low
Crushing / compressivestrength to 10% deformation
156kPa 60kPa 83kPa
Cross breaking strength 240kPa NA 186kPa
Thermal conductivity(see table 4)
0.032 W/mK 0.041 W/mK 0.042 W/mK
Thermal Control(see table 4)
Best Good Better
Recyclable Yes Reusable Yes
Workability Excellent. Norequirement for
protection.Resistant to
pedestrian traffic(1 person/m2)
Protective clothingand dust masksrecommended.
No pedestrian traffic crawl boards
required.
Excellent. Norequirement for
protection.Resistant to
pedestrian traffic(1 person/m2)
Span capabilities ofpanel. See Table 6
Best Good Better
Acoustics of panel 25 STC 30 STC 22 STC
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WARRANTYBondor New Zealand Ltd typically supply a 15 year product warranty, and a 2 year labour
warranty subject to design conditions and maintenance. Contact Bondor New Zealand or
refer to Bondor New Zealands Design Guide or Maintenance Guide for further information.
1. Details and specifications in this brochure may change without notice.2. While every care has been taken to ensure the accuracy of information no responsibility will be accepted for any errors or
ommissions.3. All information supplied applies only to products manufactured, supplied and tested by Bondor New Zealand Ltd and companies
owned by Austral Comnia Holdings PTY Ltd. Use of the information in this document for generic specification is a breach ofcopyright. Substitution with other panel manufacturers products may contravene The Building Act 2004, and is at the buyers risk.
TABLE 7
DIMENSIONS ANDTOLERANCES
BuildingComponent
Profile Effective Cover+-1mm
Min. Length+-5mm
Min. RoofPitch
WALLS CEILINGS Flat, Ribbed, Satin Line 1200mm 1200mm NA
ROOFING MetricMin thickness 150mm
for residential
1000mm 1200mm 3o
Bondor NZ All WeatherRoof (Pan)
1o00mm 1200mm 4o
Freezer Roof / FlatFully supported
1200mm 1200mm 3o
Roof pitches will very depending on siteconditions, loads, purpose, configuration, snowloading and span requirements.
Under the building code insulated panel usedas a cladding is an Alternative Solution andrequires specific design. In a roofing applicationBondor NZ panel satisfies the requirements ofthe NZBC External Moisture-Clause E2, whencorrectly specified and installed with flashingswhich direct the flow of water away from thebuilding envelope.
MANUFACTURING PROCESSBondor New Zealands insulated panel manufacturing processroll forms & laminates two skins of steel to the selected coreusing a CFC-free two part thermosetting polyurethane systemapplied in a controlled temperature environment.
CORE COMPARISONS Continued
Contact Bondor
New Zealand or refer toBondor New Zealands
Design Guide or
Maintenance Guide for
further information.
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0800 430 430Email [email protected] www.bondor.co.nz
BAY OF PLENTY
11/19 Rerewai Place,Mt Maunganui. 3116Telephone: 07 574 3246Fax: 07 572 0922
DUNEDIN
137 Main South RoadPO Box 13-057, Dunedin 9013Telephone: 03 488 3087Fax: 03 488 1731
AUCKLAND
60 ORorke Road, PenrosePO Box 11-169, Ellerslie,Auckland 1061Telephone: 09 580 6600Fax: 09 580 6616
CHRISTCHURCH
51 Buchanans Road, SockburnPO Box 11-106Christchurch 8042Telephone: 03 342 8890Fax: 03 342 6176
All information contained in this brochure is available in
PDF format at www.bondor.co.nz
REVISED AND REPRINTED JULY 2011
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